Systems and methods for supporting an object to be printed in an additive manufacturing process are disclosed. Support structures (202, 302, 402, 502, 602) are prefabricated and positioned in the build area of a 3D printing device prior to printing the 3D object. When the object has been printed, the support is removed and can be reused to print another object by repositioning the support structure in the building area of the additive manufacturing device.

Provided is a manufacturing method for a printed matter including a medium and a three-dimensional pattern printed on a surface of the medium. The three-dimensional pattern has a partly-coated resin portion and further has layers including a colored layer and clear layers formed on the colored layer. The three-dimensional pattern is formed by stacking the layers formed of inks at least containing resin on one another. One of the clear layers formed on an outermost surface of the three-dimensional pattern is flattened for a longer duration than at least one of the other one of the clear layers and the colored layer that are formed below the clear layer on the outermost surface, so that the one of the clear layers on the outermost surface is further flattened than at least one of the other one of the clear layers and the colored layer.

Thermoplastic 3D objects are printed directly onto permeable materials with a high strength bond. The 3D object can be attached to the permeable material at one side where the bottom layer of the 3D object can be attached to the permeable material or alternatively, at an internal layer where portions of the 3D object are on opposite sides of the permeable material. In order to improve the adhesion of the 3D object to the permeable material, the bonding layer of the liquid thermoplastic material that is printed directly onto the permeable material can be deposited at modified 3D printer settings that can include a hotter than normal material deposition temperature. Additional build layers of the liquid thermoplastic material are printed on the bonding layer to complete the 3D objects.

Thermoplastic 3D objects are printed directly onto permeable materials with a high strength bond. The 3D object can be attached to the permeable material at one side where the bottom layer of the 3D object can be attached to the permeable material or alternatively, at an internal layer where portions of the 3D object are on opposite sides of the permeable material. In order to improve the adhesion of the 3D object to the permeable material, the bonding layer of the liquid thermoplastic material that is printed directly onto the permeable material can be deposited at modified 3D printer settings that can include a hotter than normal material deposition temperature. Additional build layers of the liquid thermoplastic material are printed on the bonding layer to complete the 3D objects.

The invention relates to the use of a compatible thermoplastic material (film, sheet, or raft) as the base sheet or layer for 3-D printing an article. The use of the base film provides a means of printing a large article, and of reducing warpage by printing directly on the film. The printed article adheres to the film better than to traditional printer surfaces (glass, metal, glue, or reusable films), because the printed article and film weld together by forming chain entanglements, due to being compatible, miscible, or semi-miscible in the melt.

The invention relates to the use of a compatible thermoplastic material (film, sheet, or raft) as the base sheet or layer for 3-D printing an article. The use of the base film provides a means of printing a large article, and of reducing warpage by printing directly on the film. The printed article adheres to the film better than to traditional printer surfaces (glass, metal, glue, or reusable films), because the printed article and film weld together by forming chain entanglements, due to being compatible, miscible, or semi-miscible in the melt.

In manufacturing an electrothermal heater mat, there is provided a preform which comprises a laminated stack of dielectric layers which are made of thermoplastic material and include a central layer or group of layers which include(s) reinforcement and first and second outer groups of layers which do not include reinforcement. The preform includes a heater element and the preform has a first configuration. The preform is then heated to a temperature (e.g. 180 C.) between the glass-transition temperature of the thermoplastic material and the melting point of the thermoplastic material, and the heated preform is formed into a second configuration which is different to the first configuration so as to produce the heater mat.

Methods and systems are disclosed for three-dimensional printing directly onto an article of apparel. Disclosed is a method and system for direct three-dimensional printing onto an article of apparel, including positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using a three-dimensional pattern, curing the printed material, and removing the article from the three-dimensional printing system.

Methods and systems are disclosed for three-dimensional printing directly onto an article of apparel. Disclosed is a method and system for direct three-dimensional printing onto an article of apparel, including positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using a three-dimensional pattern, curing the printed material, and removing the article from the three-dimensional printing system.

Hybrid composite materials including carbon nanotube sheets and flexible ceramic materials, and methods of making the same are provided herein. In one embodiment, a method of forming a hybrid composite material is provided, the method including: placing a layer of a first flexible ceramic composite on a lay-up tooling surface; applying a sheet of a pre-preg carbon fiber reinforced polymer on the flexible ceramic composite; curing the flexible ceramic composite and the pre-preg carbon fiber reinforced polymer sheet together to form a hybrid composite material; and removing the hybrid composite material from the lay-up tooling surface, wherein the first flexible ceramic composite comprises an exterior surface of the hybrid composite material.